Arch and wall construction



Jan. 18, M, BEALL 2,1 05,804

I I ARCH AND WALL CONSTRUCTION y Filed June ll, 1934 3 Sheets-Sbeet 1 37 INVENTQR 43 Lee M Baa/l.

Jan. 18, 1938; A

ARCH AND WALL CONSTRUCTION Filed June ll, 1934 l 3 Sheets-Sheet 2 INVENTOR Lee M. 560// BY ATTORN EY ai d/ v. 22222224 22222229 22222222229 22222222222 2222222 ,4222224 w aww 2222227 22227@ 22222222222& 2222222222 v 22222222222? 3 ...u e e h Au S v e e h s 3 L. M. BEALL ARCH AND WALL CONSTRUCTION Filed June ll, 1934 .vah. s, 1938.

INVENTOR Lee M Beg/l AfioRNEY -9" m 18?" I u 2, 105,804

UNITED 'STATES PATENT OFFICE ifi i Applicatior ?iki-:91:10. 730.903

This invention relates to arch and wall contional view through one'side of the arch particustructions and particularly to the arches and larly illustrating the londing of the refractory reiractory walls oi fire boxes in boiler or like elements. furnaces. p Fig. 3 is a vertical longitudinal section through Refractory arches and walls as heretofore conthe arch portion of the fire box., 5 structed require repair and replacement after Fig. 4 is a detail perspective view of one of the periods of intense furnace Operations. such rehanger castings. pair is not only expensive in itself, but also in- Fig. 5 is a detail perspective view of one of the creases cost of power plant operation, due to T bars tor supporting the girder protection sec- 1 tying up of the pow`er plant equipment during tion of the arch the outage periods. v Fig. 6 is a detail perspective view of one of the I have found that rapid deterioration of the hanger sections tor supporting the inclined porrefractory walls is brought about in considerable tion of the arch. i l A measure by mechanical conditions produced in Fig. '7 is a detail perspective view of one of the the fire box and acting to eflect disintegration oi ignition arch tile hangers. 1 the reira'ctory material at temperatures below Fig. 8 is a detail perspective view of one of the that of their softening point. For example, exstraight refractory elements pension' and contraction under changing tem- Fig. 9 is a similar view of the refractory eleperature conditions causes cracking and dropment as viewed from the opposite side.

ping ofi of portions of the, refractory elements, -Fig, 10 is a similar perspective view of one of 20 leaving pockets which are rapidly increased in the angular refractory elements. size because of spalling ofi' of unsupported ad- Flg. 11 is an enlarged detail 'section on the lin jacent portions and by erosion produced by the li-I Fig. 3, particularlyillustrating the bondincreased turbulent effect of the gases playing ing of the retractory elements and the gasket in the pockets. material inserted between the elements to pre- 25 The slag collecting' on and running down the vent welding together of 'adjacent elements. refractory surfaces further wears away the re- Referring more in detail to the drawi'ngs: fractory elements and may bridge the joints to I designates the fire box of a furnace such as such an extent as to'interfere with the normal employed in the flring of large boilers as used expansion and contraction of the fire box and in commercialpower plants and which includes 30 the refractory elements. i side walls 2 and 3 and a fire arch 4 which ex- It is, therefore, the .principal object oi' the tends across the fire box above a grate 5, as in present invention to provide a refractory conconventional turnace design. struction which will better withstand these rav The side walls 2 and 3 of the fire box are lined aging efiects within a fire box, thereby prolongwith rei'ractory material comprising blocks or 35 ing the operation periods of a fumace. tiles laid up in bonded relation in substantially i Other important objects' of the i'nvention are the same manner as the brick on the exterior side to provide a bonded tile arrangement in an arch, and have their upper portions shaped to provide to facilitate installation and replacement of the up rdly and rearwardly i ed ledges 6 con- 40 refractory elements, to reduce cracking tendency forming t the s de contur of the ar 4 d 40 of the elements under expansion and contraction, Whereon the Sides Of the arch Overlap as shown to prevent dropping out of portions of the ele; `in Fle'- ments, `to prevent adjacent tiles from welding The arch 4 includes an' in'clined portion 'I which together, to prevent channelling efiects 'of the iS also assembled om efracto y blocks or tiles slag; and to prevent fusing 'of the'slag with the 8 and Suspended in juxtaposed relation from 45 refractory elements at the joints. hanger members 9 that are Suspended or sup- In accomplishing these and other objects of ported from girders ll) forming part of the structhe invention, I have provided improved details tural frame work 'of the furnace. The arch also' of structure, the prferred form of which is illusincludes an upwardly extending girdr protection trated in theaccompanying drawings, wherein: section ll comprising-similarly assembled re- 50 Fig. 1 is a,` perspective view of the interier of fractory tiles anchored to vertically positioned a fire box equipped with refractory wall and arch bars |2 in line with the hanger members 9, as

construction embodying the features of the presbest illustrated in Figs. 1 and 3. ent invention. The hanger members 9 include cast sections Fig. 2 is an enlarged detail perspective sec- 13 of I-shaped cross section to provide laterally 55 '20 and a socket 2l, respectively. In the illustrated instance, the hanger members include two sections secured together by a bolt or the like 22 `extending through the tongue and socket connection therebetween.

The lower ends of the hanger members thus constructed are Suspended from the cross girders i by means of rods 23 which Carry stirrups 24 engaging the teeth IS of the -ribs I'I and s, while their upper ends are secured to arcuate shaped castings 25 supporting the nose of the arch as later described, the castings 25 being in turn supported by hanger castings 26 attached to the upper cross girder 10 which carries the girder protection section of the arch.-

The castings 26 incligeovertical fianges 21 and 28 aligning with corr nding vertical flanges 29 and 30 on the bars |2 which have their lower ends extending above shelves 3| on the castings 26. The shelves 3| support the tiles which form the girder protection section li so that the nose and inclined portion of the arch can be replaced without disturbing the girder protection section.

The nose castings 25 include arcuate segments havingtile supporting flanges 32 and 33 corresponding with the tile supporting flanges previously described.

It is a purpose of the present invention to avoid rapid deterioration of the arch by providing an improved form of tile of smaller size and shape to eflect a bonded structure when they are con- .nected to the hangers. The tiles are also so shaped that sections of the arch may be readily repaired without completely rebuilding the arch.

My improved form of tiles include alternate transverse courses of straight tiles 36 as shown in Fig. 9, and intermediate courses of angularly arranged tiles 31, as shown in Fig. 10 to provide -a bonded arrangement of the head joints between the respective courses.

The straight tile 36 comprises a substantially rectangular shaped block having parallel front and rear bed faces 38'and 30, head faces 40 and 4| and end faces 42 and 43. The inner head face 40 has its upper end provided with a transverse notch 44 to accommodate the lateral flanges of the respective members as shown in Fig. 2, that 'portion 45 of the head face above the notch being inset from the lower portion 46 to accommodate the vertical web portions of the hangers so that the blocks can be Suspended from the respective side flanges thereof in such a manner that when the head faces 40 of the tiles on the same hanger are in abutment and have their head faces ,4l in abutment with those of tiles suspended on adf jacent hangers, the tiles are flrmly keyed in sus'- pended relation on the 'hangers-and the bottom ends 43 form the inner surface of the arch.

The angular blocks shown in Fig. 10 have their upper ends conformi'ng exactly to the shape of the tiles illustrated in Fig. 9, but the lower ends 41 are offset angularly therefrom to position the end faces 48 thereof so that the head joints 40 and 50 are oifset from the vertical center line of the hangers to lie substantially midway of the width of the straight tiles.

-It is thus apparent that when the straight tiles are used in one course across the width of the arch and the angular tiles in the next course, the joints 49 and 50 will be offset from the similar joints l and 52 of the straight tiles to form a bonded arch construction with the longitudinal joints in broken or staggered form.

It is apparent, therefore, that slag collecting on the under surface of the arch cannot run directly down the joints from the top to the bottom thereof because the joints of one course are broken by the tiles in the adjacent course as clearly shown in Fig. l.

In order to key the adjacent courses' of tiles together in interlocking relation, one bed face is provided with a plurality of regularly arranged diamond shaped projections 53 and the other bed face with diamond shaped recesses 54 so that the projections of tiles in on'e course interengage recesses of those in the next course as shown in Fig. 11. The projections of one face and the recesses of the other face of the tile have portions of different elevation with respect to the face of the tile, which portions form a transverse interlock with the com-plementary portions of the adjacent tile.

To prevent the slag from running across `the face of the arch from the top to the bottom thereof, the lower edge of the side faces of each tile are preferably provided with slight rabbet grooves 55 and 56 to make transverse channels extending entirely across the width of the arch and to form breaks in the smooth surface so that the slag will drop from the lower edges of the tiles. This is particularly advantageous in inclined arches, but may be eliminated in flat arch Construction.

In order to facilitate'insertion of 'the tiles as in making. repairs and in assembly of the original arch, the upper corners opposite the notches 44 are rounded, as at 51, to permit straightening of the tile after the notched or hooked haped end is engaged over the flange of the hangers as shown in Fig. 2. By thus rounding the corner to the tile, the tile is readily moved into parailel juxtaposed relation with the adjacent tile.

The nose tiles 58 are of the same Construction as the tile shown in Figs. 9 and 10, but are of' sector shape to conform to the nose of the arch.

The ignition arch brackets 59 are Suspended from the front girder in corresponding spaced relation' to the hanger members of the arch and carry flanges 60 and 6| for supporting tiles simi- .lar to 'those ofrthe main arch.

In assembling an arch from my improved form of tiles '8, the ignition arch is constructed by applying straight tiles 36 on the flanges of the ignition arch brackets so that a course extends across the entire width of the fire box and the tiles at the end of the row overlap the shoulders 6. A course of angular tiles 31 is then applied to the hangers so that the joints thereof are in offset relation to the joints in the first course. Another course of straight tiles is applied to the hangers and so on until the nose of the arch is reached where the sector tiles are used;

After forming the nose, the vertical portion of the ignition arch is completed with the flat tiles. Stop castings 62 are then applied to the lower end of the hangers 9 and alternate courses of straight and angular tiles are hung from the fianges thereof until the nose of the arch is reached. The sector tiles are then applied to the castings 25 to form the rounded nose as shown in Fig. 1.' When the nose is completed, the girder protection section of the arch is built up of the flat tiles in the same manner as the inclined portion of the arch.

. It is desirable that as each tile is inserted, a

63 be applied in the head joints of adiacent tiles as indicated in Fig., 11 to prevent escape of furnace gases therebetween.

The asbestos cloth is also very important as it prevents welding of adjacent tiles together under the extreme beat conditions in the fire box. The asbestos cloth appears to have a neu- 'tral action to slag and the two will not bond together. The tiles, therefore, remain loose so that they can freely accommodate themselves to expansion and contraction independently of each other. It is common experience with sus-` pended arches that spaces are developed between some of the tiles, after the first flring, due to shrinkage `of the tiles following their thermal expansion, and that upon subsequent operation of the furnace, slag will wash in these openings,

or cracks and cause erosion -along the joints.` The yieldable packing forms an expansion joint which accommodates expansion and contraction of the tiles without opening up the joints."

By forming the tiles in each section'with joints extending in 'the plane of the hangers as well as between the hangers, the'tiles are more easily assembled on the hangers because each individual tile is applied to the hanger at the point at which it is to be installed, as distinguished from* other constructions wherein the tiles must be inserted upon or between the ends of the hangers and slid along the hangers into the position thatit will assume in the arch structure. Another advantage is that the tiles'being of smaller-size are of lighter and more uniform weight, and are more easily handled and have less shrinkage. The smaller size also permits more uniform texture and better tensile strength throughout the thickness of the tile. i

Also, due to the fact that each tile has a single effects above referred to.

Due to the fact that the slag readily drips from the tiles, it does not tend to collect in the joints to cause welding together of adjacent tiles. The tiles are, therefore, free to move to accommodate themselves to expansion and contraction as the arch heats and cools. V

Should any -of the tiles tend to crack across the face thereof, the cracked portions cannot drop into the fire box since they are securely held by the interlocked projections'on 'the additions to which they are subjected in the furnace.

What I claim and desire to secure by Letters Patent isz' 1. In a refractory construction including spaced supporta' courses of' stralghttiles' suspended from said supports, interposed courses of tiles Suspended between the courses of straight v tiles and having angularly extending lower ends positioned in overlapped relation to the ends of two adjacent straight tiles to provide bonded joints in the longitudinal direction of said-supports, and a multiplicity of interengaged projections and recesses on contacting faces of the 'tiles which are positioned transverselyof said supports and arranged close to'one another and i each comprising but a small fraction of the tile's area and thickness to'prvent dropping out of portions of the tiles that may be cracked incidental to expansion and contra'ction in a direction transversely of the supports 2. In a refractory' construction including in-` cllned spaced supports, courses of straight tiles Suspended from said supports interposed courses of tiles suspended between the courses 'of straight I tiles and having lower ends positioned in overlapped relation to the ends of two adjacent straight tiles to provide bonded joints in the longitudinal direction of said supports, and a multiplicity of interengaged projections' and recesses on contacting faces of the tiles which are positioned transversely of said supports and arranged close to one another andeach comprising buta. small fractionof the tile's' area and thickness whereby the projections are kept in interengagement responsive to weight of the tiles tending to move them toward the lower ends of the supports to prevent dropping out of portions of the tiles that may be cracked incidental to expansion and contraction of the tiles in a direction transversely ofthe supports.

3. In a refractory construction including in- 'cllned supports having lateral flanges, courses of straight'tiles having notched upper ends for engaglng the flanges, interposed courses of tiles having notchedupper ends engaging the flanges and Suspended between.the courses of straight 40 tiles and having lower ends positioned in overlapped relation to the faces of two adjacent' straight tiles to provide bonded joints in the f longitudinal direction of said supports, and a multiplicity of interengaging projections and e recesses on the-faces of the tiles extending parallel with said courses transversely to the direction of said supports, said projections and recesses being arranged close to one 'another and each comprising but a' small fraction of the tile's area and thickness whereby the projections are kept in inte'rengagement responsive to weight of the tiles tending to move them toward the lower ends of the supports to prevent dropping out of portions of the tiles that may be cracked incidental 5 to expansion and contraction of the tiles in a direction transversely of the supports. f

4. In a refractory construction including inclined spaced 'supports having lateral flanges,

. courses of straight tiles having notched upper ends for engaging the flanges, interposed courses of tiles having similar shaped notched ends and angularly ofiset lower ends positioned in overlapped relation to the lower ends of two adjacent straight tiles to provide joints in the longitudinal direction of the supports, and a multiplicity of regularly arranged and interengaging substantially diamond-shaped key portions 'on the overlapping faces' of the tiles whereby the key portions are kept in interengagement responsive to weight of .the tiles tending to move them toward the lower ends of the supports to prevent drop- .ping out of portions of the tiles that may become cracked incidental to expansion and contraction 76 of the tiles in a direction transversely of the supports. v i

5. In a refractory Construction of the character described in combination with spaced supports, a course of straight tiles engaged with said supports and a juxtaposed course of angularly offset tiles engaged with the supports and having lower ends of substantially the same dimensions as the lower ends of the straight tiles, and a multiplicity of complementary projections and recesses of uniform size and shape and arranged in regular pattern whereby the projections on the bed face of o'ne tile interengage the recesses of an adjacent tile.

`6. An arch comprising alternately arranged courses of straight and angular tiles, lnterlocking means on said tiles to prevent independent sliding movement of the tiles in one course' relatively to the Contacting tiles in adjacent courses, and means suspending the tiles.

7. An arch comprising alternately arranged courses of straight and angular tiles having interengaging diamond shaped key portions arranged on bed faces of the respective tiles to prevent independent movement of -the tiles in one course relatively to the tiles in a juxtaposed course, and means suspending the tiles.

8. An arch comprising an arch support, and juxtaposed courses of tiles having tiles in one course in st'aggered relation to-the tiles in. the adjacent courses, and means suspending the tiles from the arch support, the tiles having bed faces,

provided with interengaging seats to intert with projections on contacting faces of similartiles in a juxtaposed course. i

9. A furnace arch structure comprising a plurality of refractory tiles each having a face formed With a plurality of interlocking portions of difierent elevation` with respect to said face distributed alternately both longitudinally and transversely thereof, and means'engaging said tiles at their upper ends to support them in depending position and collateral association with interlocking portions of one tile intermeshed with interlocking portions of another.

10. A furnace structure comprising a plurality of refractory tiles arranged in courses and each having a face formed with a plurality of narrow interlocking portions of different elevation with respectto said face arranged alternately in rows both longitudinally and transversely thereof, the tiles in respective courses being disposed in staggered relationship to those in juxtaposed courses with said interlocking portions of respective tiles of one course in interfitting relationship with interlocking portions of like faces of a plurality of tiles of a juxtaposed course.

' LEE M. BEALL. 

